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OWNER’S MANUAL AIR-COOLED DIESEL GENERATOR SET Model AED6500S/AED6500S3

PREFACE

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PREFACE Thank you for purchasing products from our company .We appreciate your business. The following manual is only a guide to assist you and is not a complete or comprehensive manual of all aspects of maintaining and repairing your generator. The equipment you have purchased is a complex piece of machinery. We recommend that you consult with a dealer if you have doubts or concerns as to your experience or ability to properly maintain or repair your equipment. You will save time and avoid the inconvenience of having to go back to the store if you choose to write or call us concerning missing parts, service questions, operating advice, and/or assembly questions. Our air-cooled diesel generators have some of the following features:

Lightweight construction

Air cooled

Four-stroke diesel internal combustion engine

Direct fuel injection system

Recoil starter or an optional electric starter

Large fuel tank

Automatic voltage stabilizer

NFB circuit protector

AC and DC outputs

Low oil pressure sensor

APOLLO brand air-cooled diesel generators are widely used when electrical power is scarce. Our generators provide a portable mobile solution in supplying power for field operations during project construction. Some other known applications include pipeline construction and metal welding when electrical power is not available.

This manual will explain how to operate and service your generator set.

If you have any questions or suggestions about this manual, please contact your local dealer or us directly. Consumers should notice that this manual might differ slightly from the actual product as more improvements are made to our products. Some of the pictures in this manual may differ slightly from the actual product as well. APOLLO POWER INDUSTRIAL CORP. reserves the right to make changes at any time without notice and without incurring any obligation.

TABLE OF CONTENTS

TABLE OF CONTENTS Chapter 1 Technical Specifications and Data……………………….1

1-1 Technical specifications and data…………………………………….1

1-2 Basic operating parameters……………………………………………2

1-3 General dimensions and overview of the generators……………….2

Chapter 2 Operating the Diesel Generator…………………………...3

2-1 Main points of safety during operation of the generator..…………..3

2-2 Preparation before operation………………….………………………4

2-3 Checking the operation of the diesel engine….……………………..7

2-4 Starting the generator set…………………….………………………..7

2-5 Proper operation of the generator set……….……………….……….8

2-6 Loading……………………………….………………………………….9

2-7 Stopping the generator……………………………………………….10

Chapter 3 Maintenance……………………………………………………..11

3-1 Maintenance schedules………………………………………………11

3-2 Storing for long periods of time……….……………………………..12

Chapter 4 Troubleshooting…………………………….………………….13

4-1 Troubleshooting procedures…………………………………………13

4-2 Questions and doubts……………….………………………………..13

Chapter 5 Generator Parts Diagrams and Listings…….………..14

Chapter 6 Circuit diagram………………………………………………….20

TECHNICAL SPECIFICATIONS AND DATA

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CHAPTER 1 TECHNICAL SPECIFICATIONS AND DATA

1-1 Technical specifications and data APOLLO Single-cylinder diesel generator

Model Item AED6500S AED6500S3

Rated frequency (Hz) 60 60

Rated voltage (V) 220、230、240、110/220、115/230、120/240 380/220、400/230、420/240

Rated output power (kVA) 5.0 5.0 Max output power (kVA) 6.3 6.3 Rated rotation speed (rpm) 3600 3600

Power factor cosφ 1 1 Phase number Single Three Pole number 2 3 Excitation Transistorized self-excitation , Brushless self-excitation constant

voltage (AVR) ATS type without ATS without ATS Fuel consumption (g/kw.h) 340 340 Fuel tank capacity (L)(US.gal) 14.5(3.8) 14.5(3.8)

Continuous running time (hr)(at rated power) 8 8

Noise level [dBA/7m] (zero load～full load) 69-74 69-74

Net weight (kg)(US.lbs) 165(363) 165(363) Overall dimension [mm](L×W×H)(US.inch)

920×520×700 (36.2×26.5 ×27.6)

920×520×700 (36.2×26.5 ×27.6)

Starter system electric starter electric starter

Fuel type 0# (summer),－10# (winter), －35#(chill cold) diesel

0# (summer),－10# (winter), －35#(chill cold) diesel

Lube oil brand CD or better than CD CD or better than CD Engine model CF186F(E) CF186F(E)

Engine type Single cylinder,

4-stroke,air-cooled,vertical,diesel engine

Single cylinder, 4-stroke,air-cooled,vertical,

diesel engine Bore × stroke(mm) 86×72 86×72 Displacement(cm3) 0.418 0.418 Compression ratio 19：1 19：1 Rated power [kW(Hp)/rpm] 5.8(7.9)/3600 5.8(7.9)/3600

Max. power [kW(Hp)/rpm] 7.3(10.0)/3600 7.3(10.0)/3600

Rotation direction(from the flywheel) clockwise clockwise

Note: Get this power only after 30 hours’ initial run.

OPERATING THE DIESEL GENERATOR

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1-2 Basic operating parameters

1-2.1 Under the given conditions, the generator will output the specified power in the table listed below.

Table 1 Height above sea level (ft) Ambient temperature (

oF) RH

0 +60 (+20 oC) 60%

<3280.8 (<1000 m) 41~104 (5-40 oC) 90%

1-3 General dimensions and overview of the generators

1-3.1 AED6500S/AED6500S3 dimensions of the series generator.

A E D 6500 S

Silent Model Diesel Generators Apollo


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CHAPTER 2 OPERATING THE DIESEL GENERATOR

2-1 General main points of safety during operation of the generator set.

In order to operate the generator set safely, please follow all the instructions provided in this manual carefully. Doing so otherwise may lead to accidents or equipment damage. 2-1.1 Fire prevention The proper fuel for the diesel generator set is light diesel fuel. Do not use gasoline, kerosene or other fuels other than light diesel fuel. Keep all flammable fuels away from the generator as the generator may spark and ignite these gases. In order to prevent fires from occurring and to provide enough ventilation for people and the machine, keep the diesel generator at least 1.5 meters away from buildings and or other equipment. Always operate your diesel generator on a level site. If the generator is operated on an incline, the lubricating system within the engine will not perform well and may lead to failure of the engine. 2-1.2 Prevention from inhaling exhaust gases. Never inhales exhaust gases emitted by the engine. The exhaust gases contain toxic carbon monoxide. Never operate your generator in places with poor ventilation. In order to operate this machinery indoors, a suitable ventilation system for the building is required to draw the poisonous exhaust gases out. 2-1.3 Prevention from accidental burns Never touch the muffler and its cover when the diesel engine is running. Never touch the muffler and cover after the diesel engine has been used, as the muffler remains hot for a good period of time. 2-1.4 Electric shock and short circuits Never touch the generator if the generator is wet. Also never touch the generator if your hand is wet. Never operate your generator if the weather conditions call for any type of precipitation such as rain, snow, or fog. To prevent electrical shocks, the generator should be grounded. Use a lead to connect the grounding end of the generator to the grounding surface of choice. Please refer to Fig. 2-1 before beginning to use the electric generator.

Fig. 2-1 Note: When connecting devices to

the generator, make sure all other devices are rated lower than the generators output. Any generator socket should not be overloaded over its regulated limit.


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2-1.5 Other safety points Before operating this generator, all operators should have a good knowledge of how to break the circuit if any accidents occur. Also, all operators should be familiar with all the switches and functions of the generator before using this machine. While operating the generator, wear safe shoes and suitable clothes during operation. Always keep children and animals away from the generator.

2-1.6 Battery The electrolytic liquid of the battery also known as battery acid contains sulfuric acid. In order to protect your eyes, skin, and clothing, wears protective gear when working with the battery. If you come in contact with the electrolytic liquid, wash it immediately with clean water. Also, if the electrolytic liquid comes in contact with your eyes, see a doctor immediately.

2-2 Preparation before operation 2-2.1 Fuel choices and fuel treatment

Fuel tank

Use only light diesel fuel. The fuel should be filtered clean. Never let dust and water mix with fuel in the fuel tank. Otherwise it will clog the fuel lines and oil nozzles. It may also damage your pressure pump.

Note: It is dangerous to overfill the fuel tank. Never exceed the red piston in the filter.

Type AED6500S AED6500S3

The effective volume of fuel tank: (L)(US. gal)

14.5 （3.8）

14.5 （3.8）

a. After purchasing fuel, put it into a drum and let it sit for 3-4 days. b. 3-4 days later, insert half of the fuel sucker into the drum, (water and

impurities stay in the lower portion of the drum)

Air filter element

Do not wash the air filter. The element is made of dry material, which does not permit washing. When the output of the diesel engine is bad or the color of the exhaust gas is abnormal, replace the air filter element. Never start the diesel engine without the air filter.

NOTE: Never smoking near the opening of the fuel tank. Do not let sparks get near the fuel or fuel tank and do not overfill tank. After filling, tighten the fuel cap.

Air filter


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2-2.2 Filling engine oil

Remove the dipstick from the engine

Make sure the generator is on level ground, and fill the engine with 15W40 engine oil. Put the dipstick back into the hole to check the engine oil level.

Engine oil is the most important factor in determining the life of your generator engine. If you use poor engine oil or if you don’t change the oil regularly, the piston and cylinder will wear easily or seize up. Also, the life of the other parts in your engine such as bearings, and other rotating parts will shorten considerably.

Although there is an alarm system to check for low oil pressure, it is always a good idea to check the amount of oil inside the engine. If the oil level is low, fill it before starting the engine. A good time to drain the oil from the engine is when the diesel engine is still hot. If the engine is fully cooled, it is more difficult to drain all the oil out or some impurities will remain in the engine.


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2-2.3 Checking the air filter

(1) Loosen the butterfly nut, take the cover of the air filter off and take the air filter element out.

Do not use detergent to wash the air filter element. When the performance of the engine decreases or when the color of the exhaust gases is bad, exchange the filter element. Never start the engine without the air filter as foreign objects may enter the intake and damage the engine.

(2) After replacing the air filter element, replace the cover and tighten the butterfly nut firmly.

Use dry compressed air (with pressure about 1.96 x 105 Pa) to blow the dust out in the electric control cabinet and at the surface of the generator. Check to see how clean the surface of the sliding ring is. Check the pressure of the carbon brush. Also, check whether the position of the carbon brush at the slide ring is correct and the fixture is reliable with a good contact.

According to the electric wiring diagram, check to see whether the connecting wire is correct and the connected place is firm.

Use a 500 M Ω meter to measure the insulation resistance of the electrical part. The resistance should be no less than 5M Ω. When measuring devices, make sure the AVR is turned off. Otherwise, it will burn the AVR. (For the low noise set, the inspection may not be performed).

2-2.4 The fuel and oil in a new engine is drained before sold. Before you start the engine, please fill the fuel tank and engine oil first. Then, check to see if there are air bubbles in the engine. If there are, follow these procedures. Loosen the connecting nut between the oil injection pump and oil pipe. Bleed the air from the system until there are no more bubbles. Then replace the connecting nut and tighten it.

Air filter

Air filter cover


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2-3 Checking the operation of the diesel engine 2-3.1 Low-pressure alarm system.

APOLLO diesel engines have a low-pressure sensor system where if the oil pressure drops too low, the sensor will shut the engine off. The purpose of having this system is to ensure that the engine does not seize up. If there is not enough oil in the engine, the temperature of the oil will be raised too high. On the contrary, if there is too much oil in the engine, the engine oil can slow the engine down considerably.

2-3.2 How to open the case door/cover (1) Open the case door: Pull the

handle outward and open the door. Do these checks daily.

(2) Loosen the outer cover bolt of the air filter and outer cover of the oil nozzle, and then check the air filter.

(3) Check the outer cover of the oil nozzle. Loosen the butterfly nut and open the outer cover.

2-3.3 Engine break in When you purchase a brand new engine, the engine must be properly broken in. The break in period is about 20 hours.

(1) Avoid overloading the engine when brand new

(2) Change the engine oil according to specifications. An oil change for a brand new engine is about 20 hours or every month, an older engine, the oil change is about 100 hours or three months.

2-4 Starting the generator set 2-4.1 Starting. Start the engine in accordance with procedures below:

(1) Open the front door to put the speed handle to right side, namely “on” position.

(2) Turn the ignition switch of the engine to the “Start” position for 1~2 seconds.

(3) After starting the engine, loose the ignition switch and it will return to “On” position automatically, the engine start to work.

(4) If fail to start, please restart the engine as above steps after 15 seconds.


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2-4.2 Battery 1. Insert key into ignition and put it in the “off” position.

2. Put the speed handle in the “Run” position.

3. Turn the start switch clockwise to the “START” position.

4. After the diesel engine is started, remove your hand from the switch handle; the switch will automatically reset itself to the “ON” position.

5. If the engine is not starting after 10 seconds of cranking, wait about 15 seconds before trying it again. If you crank too long, the voltage of the battery will drop. This can lead to improper ignition. When the diesel engine is operating, let the ignition retain on the “ON” position.

Note: If you crank the starter too long, the battery may be drained too much to provide enough energy for proper engine ignition. Also, when the diesel engine is operating, let the key retain in the “ON” position.

Important Notice：

All of our units come with a maintenance free battery. You do not need to add any battery acid.

2-5 Proper operation of the generator set 2-5.1 Operating the diesel engine 1. Pre-heat the diesel engine for 3 minutes under

no load conditions.

2. First check the height of the lubricating oil level, if it is low, refill it. Our diesel engines are equipped with an alarm system that will notify you if the oil pressure is too low. The alarm system will shut down the engine if the oil pressure is too low.


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3. Do not adjust the speed limit regulation bolt or the fuel adjustment bolt. These bolts have been set by the factory already, changing them will affect the properties of the engine performance.

2-5.2 Checks during engine operation 1. Check to see if there are abnormal noises. 2. Check to see if the performance is good or bad 3. Check the color of the exhaust gases (whether it is too black or too white).

If any of these conditions exist, stop the engine and find the cause of the problem. If no problems are found, please contact your local dealer or our nearest company branch.

2-6 Loading 2-6.1 Load conditions Exert loads in accordance with the specified parameters. 2-6.2 Output of electricity 1. Raise the revolutions per minute (turn the speed handle to the max setting)

of the generator to get the maximum power out of the generator. If not, the automatic voltage regulator device will excite and doing this for long periods of time will cause the AVR to burn. For the rated speed of the generator, please refer to Chapter 1, item 1-1 technical specification and data.

2. Observe the pointer of the voltmeter; it should point to 240 V 5% (60Hz). Meanwhile put the switch in the GEN (generator) position. The AC voltage from the socket of the power supply can be output.

3. When connecting devices to the generator, make sure to connect these devices in order. Connect the large loads onto the generator first. If everything is functional, smaller loads can then be added. If the generator shuts off, it may be because the load being drawn by all the various devices are too high. In this event, decrease the number of small devices until everything is functional. The total drawn power should not exceed the maximum output power of the generator. Please see Table 1-1 for technical specifications of what the generator can output. In order to reset the generator after overdrawn power, let it sit for several minutes. If the indication of the voltmeter is too high or too low, adjust the speed accordingly. If there are problems, stop the generator immediately and fix the issue.

4. During operation, the generator should be in a place that has very good ventilation. Never cover the engine to solve a ventilation problem, as this will damage your equipment.

Note: Do not start more than two devices simultaneously. Each device should be started one by one to prevent overloading the generator. The generator should be running at 3600 revolutions per minute in order to achieve the (60 Hz) frequency. The speed of the engine can be adjusted from the speed governor.


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2-6.3 Charging the battery

1. For the electric starter on the generator sets, the 12V battery is automatically charged through the regulator on the side of the engine when it is running.

2. If the generator is not used for long periods of time, the battery should be disconnected to avoid energy loss from the battery.

3. Do not connect the negative and positive terminals of the battery together at any time. Doing so will damage the battery and cause serious injuries.

4. Do not reverse the polarities when attaching the battery cables to the battery. Doing so will damage both the battery and the electric starter.

5. When charging the battery, the battery produces flammable gases. Do not smoke, let flames, and sparks get near the battery while it is charging as this may cause a fire.

To avoid sparking while connecting the cables to the battery, first, connect the cables to the battery then to the motor. To disconnect battery cables, first disconnect the motor end of the cable.

2-7 Stopping the generator 1. Take the electrical load off the generator.

2. Put the speed handle in the “RUN” position and let the engine run for 3 minutes after unloading. Do not stop the diesel engine immediately let it warm down. Stopping the diesel engine suddenly may raise the temperature of the engine abnormally and lock the nozzle and damage the diesel engine.

Note:

1. If you cannot stop the engine with a load on it, then remove the load first than stop the engine.

2. Press down on the brake handle.

3. If equipped with an electric starter, turn the key to the “Off” position.

4. Put the fuel handle to the “S” position.

MAINTENANCE

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CHAPTER 3 MAINTENANCE 3-1 Maintenance schedules Keeping your generator well maintained will prolong the life of your generator. Everything needs to be checked including the diesel engine, generator, control cabinet, and frame. For overhauling procedures, please refer to the instruction manual of the relative subassembly. If you need these manuals, please call our company and we will send you one. Before starting the maintenance, make sure the diesel engine is off. Please refer to the Table 3-1 for the proper maintenance schedule. Table 3-1. Maintenance schedule for diesel generator set Time Item Everyday After 1 month

or 50hours Every 3 month or 200 hours

Every 6 month or 400 hours

Every 1year or 1000 hours

Check the fuel level and refill

Before starting

Drain the fuel tank Check and fill enough engine oil Clean the fuel filter Check fuel oil leakage

after every operating

Check and screw each fastened part

screw the bolt of cylinder head firmly

Check injector Check injection pump

Check fuel pipe If necessary exchange it

Check the lube. oil level in the oil pan and refill

before starting

Replace the lube. oil the first time

the second time and afterward

Clean lube. Oil filter the first time


Check the air cleaner element the first time


Change the core of air filter If damaged or smeary , change it in time

Check the battery liquid level and refill

Adjusting the intake and exhaust valve clearance

the first time the second time and afterward

Grind air intake and air exhausted gate Exchange piston ring Check electric brush and slide ring Check insulation resistance The time of stop is over 10 days Note: the quality period of the injector and injection pump is 1500 hours

or two years. There into, means it should operate with special tools, or can be checked by dealer.

MAINTENANCE

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3-1.1 Changing the engine oil (every 100 hours) Take the oil cover off. Remove the oil drain plug when the diesel engine is still hot. Be careful of hot oil and hot engine as you may get burned. The bolt is located at the bottom of the cylinder. After draining the oil, put the bolt back and tighten it. Then fill with the proper engine oil to the proper level.

3-1.2 Air filter maintenance schedule 1. Clean air-filter every 6 months or 500 hours of operation. 2. If necessary, exchange it. 3. Do not use detergent to clean air filter element.

Note: Never start the engine without the air filter. This can cause serious damage to the engine if foreign objects enter the intake system. Always change the air filter on time.

3-1.3 Fuel filter maintenance 1. The fuel filter should be cleaned often to keep the engine running at

maximum performance. 2. The recommended time period for cleaning the fuel filter is 6 months or 500

hours of operation. a. To do this, first drain the fuel from the fuel tank. b. Loosen the small screws on the fuel switch and remove the fuel filter form

the port. Use diesel fuel to clean the fuel filter. Also, remove the fuel injector and clean the carbon deposit around it. The recommended time period for this is 3 months or 100 hours.

3-1.4 Cylinder head bolt tensions The cylinder head bolts should be tightened to specifications please refer to the diesel engine manual for specifications and the special tools required to do this. 3-1.5 Battery check Make sure the battery acid is full. The engine uses a 12V battery. Due to numerous starting cycles, the battery acid may be used up. Also, before filling, verify that the battery is not damaged in any way. Add distilled water to the battery when filling. Perform checks on the battery once a month.

3-2 Storing for long periods of time If your generator needs to be stored for long periods of time, the following preparations should be made. 1. Start the diesel engine for 3 minutes then stop it. 2. When the engine is still hot, change the engine oil with new engine oil of the

proper grade. 3. For electric started generator, press the decompression handle down and

crank the engine for 2-3 seconds. To do this, put the starter switch in the “Start” position. (Do not start the diesel engine)

4. Clean the engine and store it in a dry place.

TROUBLESHOOTING

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CHAPTER 4 TROUBLESHOOTING 4-1 Troubleshooting procedures

Causes of malfunction Remedy Not enough fuel Add enough fuel The switch of fuel is not at “OPEN” position.

Turn the switch of fuel to “OPEN” position.

High-pressure pump and nozzle do not inject fuel or the injected amount is less.

Disassemble the nozzle and adjust it at test table.

Speed control lever is not at “RUN” position.

Turn speed control lever to “RUN” position.

Check level of lubrication oil.

The standard oil amount of lubricating oil should be between high graduation “H” and low graduation “L”.

It is not quick and powerful to pull reactive starter.

Start diesel engine in accordance with the requirements of “start operation procedures”.

Nozzle exist dirt. Clean the nozzle.

Die

sel c

anno

t be

star

ted.

Accumulator has not electricity. Charge the accumulator or exchange it.

Master switch (NFB) is not be switched on.

Turn master switch handle to “ON” position.

Carbon brush of generator was worn. The contact is bad. Exchange the carbon brush.

The contact of socket is bad. Adjust the contact feet of socket.

The rated revolution of engine cannot be reached.

Make it reach to the rated revolution in accordance with the requirements.

AVR automatic governor is damaged. Exchange it.

Gen

erat

or c

anno

t gen

erat

e el

ectri

city

and

has

not

wel

ding

vo

ltage

The potentiometer of current regulation for electric welding is damaged.

Exchange it.

If you are still having trouble, please contact with your nearest dealer or with our company directly if necessary. 4-2 Questions and doubts If you do not understand anything or have any questions, please feel free to contact your local dealer or with our company directly. Below is a list of some information you should have ready before contacting your local dealer or us. 1. Model of diesel engine generator and engine model number. 2. State of residency. 3. Number of hours of operating equipment along with the problem that occurred. 4. A detailed condition and time when the problem occurred, in other words,

climate and atmosphere.

GENERATOR PARTS DIAGRAMS AND LISTINGS

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CHAPTER 5 GENERATOR PARTS DIAGRAMS AND LISTINGS

Figure 5-1. Overall view of engine generator assembly


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Table 5-1. Please refer to figure 5-1 for illustration No Part Description Quantity Part Code 1 Silencer cover 1 6500S-E-001 2 Silencer bend 1 6500S-E-002 3 Left board of cover 1 6500S-E-003 4 Back door of cover 1 6500S-E-004 5 Fixing sleeve for observing bore 1 6500S-E-005 6 Fixing sleeve for input of fuel tank 1 6500S-E-006 7 Main cover 1 6500S-E-007 8 Switch of front door 1 6500S-E-008 9 Air filter baffle 1 6500S-E-009

10 stationary rings of generators 1 6500S-E-010 11 Right board of cover 1 6500S-E-011 12 Output panel assembly 1 6500S-E-012 13 Cover of observing bore for air filter 1 6500S-E-013 14 Cover of fuel tank assembly 1 6500S-E-014 15 Buoy for oil level indication 1 6500S-E-015 16 Fuel tank(not assembly) 1 6500S-E-016 17 Lining of absorbing mat 4 6500S-E-017 18 Shock absorbing mat 4 6500S-E-018 19 Clipφ9 4 6500S-E-019 20 Clipφ13 4 6500S-E-020 21 Fuel inlet pipeⅠ(φ13) 1 6500S-E-021 22 Fuel filter assembly with cover 1 6500S-E-022 23 Fuel inlet pipeⅡ(φ13) 1 6500S-E-023 24 Fuel leak-off pipe 1 6500S-E-024 25 Cover of U-type chamfer 1 6500S-E-025 26 U- type chamfer 1 6500S-E-026 27 Support of U-type chamfer 1 6500S-E-027 28 Moire output pipe 1 6500S-E-028 29 Gasket of silencer 1 6500S-E-029 30 Upper silencer 1 6500S-E-030 31 Low silencer 1 6500S-E-031 32 Back cover of alternator 1 6500S-E-032 33 Bracket of classis 1 6500S-E-033 34 Shock absorbing mat of generators 4 6500S-E-034 35 Tow structure 1 6500S-E-035 36 Rectify bridge 1 6500S-E-036 37 Wiring seat3×2 1 6500S-E-037 38 Battery cable(set) 1 6500S-E-038 39 Chassis 1 6500S-E-039 40 Rolling wheel on chassis(4 inch) 4 6500S-E-040 41 Flat washer 8 6500S-E-041 42 Pin 3×25 4 6500S-E-042 43 Motherboard of accumulator 1 6500S-E-043 44 Accumulator (maintenance free) 1 6500S-E-044 45 hook type bolt of battery 2 6500S-E-045 46 Pressing plate of accumulator 1 6500S-E-046


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No Part Description QU.T Part Code 47 clamp of accumulator with bolt and nut 2 6500S-E-047 48 cover of clamp of accumulator 2 6500S-E-048 49 Alternator assembly 1 6500S-E-049 50 Output wind leading shaft 1 6500S-E-050 51 Manostat 1 6500S-E-051 52 Gasket of output bore 1 6500S-E-052 53 Diesel engine 1 6500S-E-A53 54 Capacitor/AVR 1 6500S-E-054 55 Intake wind leading shaft 1 6500S-E-055 56 Pressing plate of high pressure fuel pipe 1 6500S-E-056 57 shock preventing mat of intake wind leading shaft 1 6500S-E-057

58 shock preventing holder of intake wind leading shaft 1 6500S-E-058 59 Cover of wheel 4 6500S-E-059 60 Fuel leak-off pipe of pipe teeφ9 1 6500S-E-060 61 Pipe tee 1 6500S-E-061 62 Fuel inlet pipe of pipe teeφ13 1 6500S-E-062 63 Support of manostat 1 6500S-E-063 64 lead of manostat 1 6500S-E-064 65 Electromagnet 1 6500S-E-083 66 Accelerator electromagnet 1 6500S-E-084 67 Pulling wire for turn-off 1 6500S-E-085 68 Pulling wire for throttle 1 6500S-E-086 69 Pulling role for accelerator 1 6500S-E-087 A Bolt M6×16with flat washer 54 6500S-E-065 B Heterotypic bolt M6×8 6 6500S-E-066 C Heterotypic bolt M6×14 6 6500S-E-067 D Heterotypic bolt M6×22 6 6500S-E-068 E Bolt M10×45with flat washer and spring washer 4 6500S-E-069 F Bolt M6×16 4 6500S-E-070 G Bolt M8×25 5 6500S-E-071 H Bolt M6×12 17 6500S-E-072 I Bolt M5×8 2 6500S-E-073 J Heterotypic nut M6 34 6500S-E-074 K Nut M8 with flat washerφ8and spring washerφ8 6 6500S-E-075 L Nut M10with flat washerφ10and spring washerφ10 12 6500S-E-076 M Bolt M5×12 2 6500S-E-077 N Bolt M6×22 2 6500S-E-078 O crossed bolt M4×22 with flat washer and spring washer 5 6500S-E-079 P Nut M4 5 6500S-E-080 Q crossed bolt M5×12 4 6500S-E-081 R Nut M5 4 6500S-E-082

* Please notice that Item 65,66,67,68 and 69 only can be supplied to the generators with mechanical injection pump. If you use electromagnetic pumps, these parts are not necessary. Please consult the dealer before make the orders.


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Figure 5-2. Electric panel parts drawing


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Table 5-2. Please refer to Figure 5-2 Number Part Description Quantity Part Code

1 Nut M4(GB/T6170-2000) 6 1000-C-001

2 Electric start switch 1 1000-C-002

3 Square American type-socket 1 1000-C-003

4 Overload protector(20A) 1 1000-C-004

4-1 Overload protector(30A) 1 1000-C-004-1

5 B-type aluminum panel 1 1000-C-005

6 Bolt M4×12(GB/T819.1-2000) 6 1000-C-006

7 Bolt M6×10 (GB/T819.1-2000) 4 1000-C-007

8 Voltmeter 1 1000-C-008

9 Bolt M3×16(GB823-88) 2 1000-C-009

10 Digital Timing 1 1000-C-010

11 Red wire holder(107) 1 1000-C-011

12 Black wire holder(107) 1 1000-C-012

13 Bolt M4×25(GB/T818) 2 1000-C-013

14 plate Washer4 9 1000-C-014

15 Nut M6 (GB/T6170) 2 1000-C-015

16 DC fuse assembly 2 1000-C-016

17 Nut M3 (GB/T6170-2000) 2 1000-C-017

18 Transfer switch302/25A 1 1000-C-018

19 American type 4-hole unit loose socket 1 1000-C-019

20 Bolt M6×26 (GB/T5787-1996) 1 1000-C-020

21 3-hole unit loose socket 1 1000-C-021

22 Breaker(DZ216-63/2P/18.5A) 1 1000-C-022

23 Nut M4 (GB/T6170-2000) 9 1000-C-023

24 Indicating lamp of power supply(12V) 1 1000-C-025

25 Low-oil protection indicating lamp(12V) 1 1000-C-026

26 2P support of breaker 1 1000-C-027

27 Fuse 10A 2 1000-C-028

28 Key 1 1000-C-029

29 bolt to the grounded 1sets 1000-C-030

30 rectifier(12V) 1 1000-C-031


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Figure 5-3. Generator head assembly

Table 5-3. Please refer to figure 5-3

Number Part Description Quantity Part Code

1 Front end cover 1 1000-B-001

2 Diode 3510 1 1000-B-002

3 Bolt M5 x 16 2 1000-B-003

4 Fan Blade 1 1000-B-004

5 Bearing 6204(GB/T 307) 1 1000-B-005

6 Rotor Unit 1 1000-B-006

7 Center bolt M10 x 216 (GB/T5789-1986) 1 1000-B-007

8 Guard board of motor 1 1000-B-008

9 Installing bolt M6×180(GB/T5789-1986) 4 1000-B-009

10 Capacitance 30mf 1 1000-B-010

11 Wiring seat 1 1000-B-011

12 Heterotypic bolt M5×14 6 1000-B-012

13 Stator unit 1 1000-B-013

14 Dust cover 1 1000-B-014

CIRCUIT DIAGRAM

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CHAPTER 6 CIRCUIT DIAGRAM

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